Interlocking Steel Plate Foundation

ABSTRACT

Disclosed are interlocking steel plate foundations of various configurations. Interlocking foundations eliminate the need for concrete foundations and have a much shorter assembly time. Interlocking foundations have fins which provide for increased torsional restriction for the same or less material than other metal foundations such as the metal fin tube style foundation. Optionally multiple foundations can also be linked together to construct foundations of any shape and size

BACKGROUND

Over the last several years, metal foundations have been used to providesupport for many different types of structures, because they offer manyadvantages over concrete foundations. Once installed, metal foundationscan be used to instantly provide support for a structure, unlikeconcrete foundations which require a significant amount of time to cure.Metal foundations also can be installed in any weather condition and onany terrain; they are less damaging to the environment and they areeasily moved when compared to concrete foundations.

One type of metal foundation is disclosed in U.S. Pat. No. 9,422,687.This invention is directed to a flat-plate foundation support whichincludes a lower portion extending longitudinally along a centrallongitudinal axis of the support and adapted for insertion into a groundsurface. The lower portion has a plurality of flat non-slotted metalplates that are mutually connected in an adjacent manner along thecentral longitudinal axis of the foundation support forming fins thatextend laterally or radially from the central longitudinal axis formedby the adjacent connection. The flat plates are beveled and have asharpened leading edge at a lower end of the lower portion. An upperportion of the support such as a pipe without slots in itscircumference; can be attached to a top end of the lower portion by asuitable method, such as welding along the lateral edges of the fins inthe longitudinal direction. The upper portion of the support is attachedto a ground supported apparatus to anchor that apparatus to the ground.However a disadvantage is for the above design is that welding is bestknown method to adjacently connect flat non-slotted plates along acentral longitudinal axis.

Welding, either on site or offsite requires qualified people and specialequipment. This adds to the expense of installing foundations. Usuallybecause it is less expensive, the metal foundation bodies are weldedtogether in a shop and then transported on to the worksite. Transportingpre-assembled metal foundations limits their size and shape. If themetal foundations necessary for a specific project are too large orawkward to transport, the individual pieces can be weld together onsite. However, this increases the expense of installing metalfoundations because all the necessary personnel and equipment must alsobe transported to the worksite. Welding also generates toxic fumes whichis not healthy for people or environmentally friendly.

A non-welding solution is provided in U.S. patent application Ser. No.14/827,477. Disclosed in this application are metal fin tube foundationsthat are assembled together without welding. In the disclosed invention,the fins are part of the metal foundation body. The bodies of the metalfoundation of the disclosed invention are assembled manually via theintegrated fins by mechanical fastening. The metal fin tube foundationsof the invention can either be a perimeter geometric shape, a radialgeometric shape or if the job requires, both shaped foundations can becombined/used in conjunction with one another. The mechanical fasteningmeans can be any known in the field including, but not limited to HuckBolts, rivets, clips, bolts, studs and clamps. However the manufacturingof these foundations can be complex and require excessive labor tomanually fasten the foundation pieces into the specific geometricshapes. This can lead to extra cost because of both the labor needed andmechanical fastening means themselves.

What is needed is: Metal foundation with greater torsional resistancethat are easier to assemble and that provide greater strength using lessmaterial that previous metal foundations. It is also desired to have adesign that can be a basis for foundations of various shapes and sizesgiving designers more flexibility to incorporate multiple designs asrequired for specific projects.

SUMMARY

What is disclosed is interlocking steel plate foundations of variousconfigurations. Interlocking foundations eliminate the need for concretefoundations and have a much shorter assembly time. Interlockingfoundations have fins which provide for increased torsional restrictionfor the same or less material than other metal foundations such as themetal fin tube style foundation. Optionally multiple foundations canalso be linked together to construct foundations of any shape and size.

SHORT DESCRIPTION OF THE FIGURES

FIG. 1A shows a top plate for one embodiment of an interlockingfoundation of this disclosure.

FIG. 1B shows a bottom plate for one embodiment of an interlockingfoundation of this disclosure.

FIG. 1C shows the assembly of an embodiment of an interlockingfoundation of this disclosure.

FIG. 2A is a top view of the interlocking foundation in FIG. 1C with anattached top mounting plate.

FIG. 2B is a side view of the interlocking foundation in FIG. 1C with anattached top mounting plate.

FIG. 3A shows a pipe with receiving slots for one embodiment of aninterlocking pipe foundation of this disclosure.

FIG. 3B shows upwards producing foundation with pipe slots for oneembodiment of an interlocking pipe foundation of this disclosure.

FIG. 3C shows the assembly of an embodiment of an interlocking pipefoundation of this disclosure.

FIG. 4A shows a top plate for one embodiment of a foundation for use ina second embodiment of an interlocking pipe foundation of thisdisclosure.

FIG. 4B shows a bottom plate for one embodiment of a foundation for usein a second embodiment of an interlocking pipe foundation of thisdisclosure.

FIG. 4C shows the assembly of an embodiment of an interlocking platefoundation for use in a second embodiment of an interlocking pipefoundation of this disclosure.

FIG. 4D shows a pipe for use in a second embodiment of an interlockingpipe foundation of this disclosure.

FIG. 4E shows the assembly of a second embodiment of an interlockingpipe foundation of this disclosure.

FIG. 5A shows a zee-shaped top plate of an embodiment of an interlockingfoundation of this disclosure.

FIG. 5B shows a zee-shaped bottom plate of an embodiment of aninterlocking foundation of this disclosure.

FIG. 5C shows the assembly of an embodiment of an interlocking bentfoundation of this disclosure.

FIG. 6A is a top view of the interlocking bent foundation in FIG. 5Cwith an attached top mounting plate.

FIG. 6B is a side view of the interlocking bent foundation in FIG. 5Cwith an attached top mounting plate.

FIG. 7 is an isometric view of the interlocking bent foundation in FIG.5C with attached straps.

FIG. 8A shows a bottom plate with legs and leg flanges of an embodimentof an interlocking angle plate foundation of this disclosure.

FIG. 8B shows a top plate with legs and leg flanges of an embodiment ofan interlocking angle plate foundation of this disclosure.

FIG. 8C shows the assembly of an embodiment of an interlocking angleplate foundation of this disclosure.

FIG. 9A is a top view of the interlocking angle plate foundation in FIG.8C with an attached top mounting plate.

FIG. 9B is a side view of the interlocking angle plate foundation inFIG. 8C with an attached top mounting plate.

FIG. 10A shows a top view of the assembly of an embodiment of aninterlocking pipe foundation of this disclosure that uses flat plates.

FIG. 10B shows a top view of a pipe used in an embodiment of aninterlocking pipe foundation of this disclosure.

FIG. 10C shows a side view of a pipe used in an embodiment of aninterlocking pipe foundation of this disclosure.

FIG. 10D shows a side view of a flat plate with slots used in anembodiment of an interlocking pipe foundation of this disclosure.

FIG. 11 shows the assembly of multiple interlocking pipe foundations ofthis disclosure.

FIG. 12A shows the assembly of an embodiment of an interlocking metalfin foundation of this disclosure.

FIG. 12B shows a top view of a metal fin used in an embodiment of aninterlocking metal fin foundation of this disclosure.

FIG. 12C shows a side view of a metal fin used in an embodiment of aninterlocking metal fin foundation of this disclosure.

FIG. 12D shows a side view of a flat plate with slots used in anembodiment of an interlocking metal fin foundation of this disclosure.

DETAILED DESCRIPTION

The interlocking steel plate foundation disclosed is comprised of two ormore flat steel plates joined together by complementary slots. Steelplates can be cut to a certain length and a certain width as required bythe specific project. This can be done by any steel plate manufacturer.Slots can then be cut into the steel plates as desired. The mosteconomic means is by a computer numeric control (CNC) plasma cutter or aCNC laser. The plates can also be hot dip galvanized if required. Noteon all the Figures holes are represented as circles, these holes are notnecessary for to understand the inventive concept nor are required, butare only depicted as potential fastening or connecting means.

One embodiment of the interlocking steel plate foundation is disclosedin FIG. 1A-1C. Bottom plate 1 has slot 2 that opens upward. Top plate 3has slot 4 that opens downward. Slots 2 and 4 are used to interlockplates 1 and 3 together to form foundation 5. The length of the slot isdetermined by the specific project that necessitates by the design ofthe foundation and how much intersection is desired between the twoplates. As shown here, the two plates are preferably identical, butunequal plates are also contemplated by this disclosure. Ideally, theplates are flush with respect to their edges on the top and the bottomof foundation 5 and therefore in the identical plates shown in thisfigure, preferably the slots 2 and 4 would be cut from the edge of theplate to the midpoint. Also preferably, the lateral sides of thefoundation are even and therefore the slots 2 and 4 would be centered.Though flush edges and lateral sides are preferred, the invention alsocontemplates uneven lateral sides and edges. The width of the slots 2and 4 are to be slightly larger than the plate thickness with which itis engaging. Fins 6 in foundation 5 provide torsional resistance whenfoundation 5 is inserted into the ground.

Interlocking assembly can occur at the manufacturer and then thefoundation can be shipped as a completed piece, or the fabricated steelplates can be transported individually and the foundation is thenassembled on site. Assembly can be done by any means. The most effectiveand easy slotting methods is using physical force to push theinterlocking pieces together; this method will suffice for mostfoundation designs. If desired optionally, the interlocking plates canbe welded or mechanically fastened together for increased stability. Onsite either the completed interlocking foundation is vibrated or pushedinto the ground or the bottom plate is vibrated or pushed partially intothe ground the top plate is interlocked via the slots and then the restof the foundation is inset into ground. In either case, a portion of thefoundation remains above ground to connect with any suitable aboveground structure or equipment the foundation was intended to support.One advantage of using the vibration method is that soil is notdisplaced from the local area; displacement of soil can beenvironmentally damaging and the removal of soil can be costly and atime burden.

This interlocking foundation can either connect directly to the aboveground structure, or it may connect via a top mounting plate as depictedin FIG. 2A-2B. Atop of foundation 5 is top mounting plate 7. Depictedhere top mounting plate 7 is comprised of a flat piece 8 with sideoverhangs 9. Top mounting plate 7 can be comprised of a single formedpiece or several individual pieces fastened together. Also note that atop mounting plate comprised of a flat piece alone that is connected tothe foundation is also contemplated by this disclosure. Mechanical meanssuch as bolts can be used fasten the top mounting plate 7 to foundation5.

Optionally, a pipe support can be used in conjunction with aninterlocking foundation as depicted in FIG. 4A-4E. Plate 11 is comprisedof central slot 12 and pipe slots 13 whereby central slot 12 is formedon the same edge of the plate 11 as pipe slots 13. Plate 14 is comprisedof central slot 15 and pipe slots 13 whereby central slot 15 is formedon the opposite edge of the plate 14 as pipe slots 13. Pipe 16 iscomprised of plate receiving slots 17 facing upwards. Plate 11 and plate14 are interlocked via central slots 12 and 15 to form foundation 18with pipe slots 13 facing downward. Pipe 16 and foundation 18 areinterlocked via pipe slots 13 and receiving slots 17 to form pipefoundation 19. Though a circular pipe is depicted here, any otherstructural shape in which slots can be cut that correspond to the slotsin the flat plates of interlocking foundation are contemplated by thisinvention. The pipe foundation can connect directly to an above groundstructure or optionally, a top mounting plate can be used for connectingto the above ground structure.

In FIG. 3A-3C is an alternative pipe support foundation. The same plateconfigurations 11 and 14 as seen in FIG. 4 are interlocked in the samemanner, however the pipe slots 13 are used facing upwards producingfoundation 58. Pipe 56 is comprised of plate receiving slots 57 facingdownwards. Pipe 56 and foundation 58 are interlocked via pipe slots 13and receiving slots 57 to form pipe foundation 59. Pipe 56 can anylength required for the specific project.

Another embodiment of the interlocking foundation is shown in FIG.5A-5C. This embodiment has increased torsional resistance. Instead ofthe plates being flat, the plates are comprised of bends that are formedinto longitudinally with respect to the plate and slots. Bottom plate 20is Zee shaped and comprised of web 22 and two leg flanges 23 and hasslot 21 that opens upward. Top plate 24 is Zee shaped and comprised ofweb 25 and two leg flanges 26 and has slot 27 that opens downward. Slots21 and 27 are used to interlock plates 20 and 24 together to form bentfoundation 28. As above, the length of the slot is determined by thespecific project that necessitates by the design of the foundation andhow much intersection is desired between the two plates. As shown here,the two plates are preferably identical, but unequal plates are alsocontemplated by this disclosure. Ideally, the plates are flush withrespect to their edges on the top and the bottom of bent foundation 28and therefore in the identical plates shown in this figure, preferablythe slots 21 and 27 would be cut from the edge of the plate to themidpoint. Also ideally the lateral sides of the foundation are even andtherefore the slots 21 and 27 would be centered. Though flush edges andlateral sides are preferred, the invention also contemplates unevenlateral sides and edges. The width of the slot is to be slightly largerthan the plate thickness with which it is engaging. The webs and flangesform bent fins 29. The bent fins 29 in foundation 28 provide torsionalresistance when foundation 28 is inserted into the ground. Any steelshapes that has bends are contemplated by this invention, including butnot limited to angle plates (1 bend) channel plates (2 bends samedirection), and as seen above Zee plates (2 bends opposite direction).

This interlocking foundation can either connect directly to the aboveground structure, or it may connect via a top mounting plate as depictedin FIG. 6A-6B. Optionally atop of foundation 28 is top mounting plate30. Depicted here top mounting plate 30 is comprised of a flat piece 31with side overhangs 32. Top mounting plate 30 can be comprised of asingle formed piece or several individual pieces fastened together. Alsonote that a top mounting plate comprised of a flat piece alone that isconnected to the foundation is also contemplated by this disclosure.Mechanical means such as bolts can be used fasten the top mounting plate30 to foundation 28. Alternatively 90 degree bends facing upwards (inopposite direction from the ground) may be incorporated made at theupper edges of the bent fins to allow for the attachment of a topmounting plate that is either mechanically fastened or welded. Ifdesired for additional stability, as depicted in FIG. 7, optionallystraps 49 connecting via their lengths adjacent bent fins 29 can beused. Straps 49 are comprised of steel strips only several inches inwidth and are connected to bent fins 29 by mechanical means. Straps 49can further prevent any slippage while inserting foundation 28 into theground and be placed on the top of, on the bottom of, or on both sidesof the foundation 28. This embodiment is preferred when multiplefoundations placed short distances apart are being used to support thesame ground structure and precise alignment is required.

Another interlocking foundation embodiment utilizes angle plates 34 and35 in which each individual plate has two interior slots in closeproximity to on either side of a central angle for form angle platefoundation 33 as depicted in FIG. 8A-8C. Though shown here with bends inaddition to the central angle, embodiments with a central angle aloneare also contemplated. When the plates interlock to form foundation 33,the intersection forms a central tube 36; increasing strength andstability. Bottom plate 34 comprised of legs 37 and two leg flanges 38and has slots 39 that open upward. Preferably the legs 37 are angled at90 degrees to one another, and preferably each leg flange 38 is angledat 90 degrees to its respective leg 37. Top plate 35 comprised of legs40 and two leg flanges 41 and has slots 42 that open downward.Preferably the legs 40 are angled at 90 degrees to one another, andpreferably each leg flange 41 is angled at 90 degrees to its respectiveleg 40. Slots 39 and 42 are used to interlock plates 34 and 35 togetherto form angle plate foundation 33. As above, the length of the slots isdetermined by the specific project that necessitates by the design ofthe foundation and how much intersection is desired between the twoplates. As shown here, the two plates are preferably identical, butunequal plates are also contemplated by this disclosure. Ideally, theplates are flush with respect to their edges on the top and the bottomof angle plate foundation 33 and therefore in the identical plates shownin this figure, preferably the slots 39 and 42 would be cut from theedge of the plate to the midpoint. Also ideally the lateral sides of thefoundation are even and therefore the slots 39 and 42 would be equallydistanced from their respective central angles. Though flush edges andlateral sides are preferred, the invention also contemplates unevenlateral sides and edges. The width of the slot is to be slightly largerthan the plate thickness with which it is engaging. The legs and flangesform bent fins 43. The bent fins 43 in angle plate foundation 33 providetorsional resistance when foundation 33 is inserted into the ground.

Optionally atop of angle plate foundation 33 is top mounting plate 50.Depicted in FIG. 9A-9B, top mounting plate 50 is comprised of a flatpiece 51 with side overhangs 52. Top mounting plate 50 can be comprisedof a single formed piece or several individual pieces fastened together.Also note that a top mounting plate comprised of a flat piece alone thatis connected to the foundation is also contemplated by this disclosure.

Using any of the above described embodiments, it is also possible to addslots toward the outer edges of the either fins or bent fins, andinterlock individual foundations together via the slotting method toincrease the platform size and the stability of the foundation. Theselarge foundations can be any number and combinations of slotted plates,pipes tubes or shapes; all of which can be connected via the sameslotting method to form a large foundation area. There is no limit toits size. Top mounting plates can be attached as required.

Another embodiment of an interlocking pipe foundation 55 shown in FIG.10A-10D is comprised of a plurality of flat plates 44; each flat plate44 is comprised of two slots 45 emanating from the same side of saidflat plate, equidistance from and very near the outer edge. Preferablyfour flat plates 44 are placed in a square configuration 48 with respectto one another with a space between adjacent corners. A plurality ofpipes 46, each pipe 46 with four slots 47 emanating from the same andequidistance from one another is then interlock with the flat plates 44via the slotting method so as to “fill in” the corners of the square. Asonly two the slots 47 in the individual pipes are used in the squareconfiguration, the other two slots 47 are open to receive a slot 45 fromadditional flat plates 44, which in turn have a slot 45 available toreceive additional pipes 46, and so on and so forth to form additionalsquare configurations 48. The foundation can grow to be any size andshape; a non-limiting example of foundation 54 is shown in FIG. 11. Theonly limitation would be the amount of flat plates 44 and pipes 46available. Top mounting plates can be attached as required.

As an alternative to using pipes, one could also use any of the severalperimeter geometric shape metal fin foundations described in U.S. patentapplication Ser. No. 14/827,477. A non-limiting example using anoctagonal shape metal fin tube foundation is shown in FIG. 12A-12D.Interlocking metal fin tube foundation 60 is comprised of a plurality offlat plates 61; each flat plate 61 is comprised of two slots 62emanating from the same side of said flat plate, equidistance from andvery near the outer edge. Preferably four flat plates 61 are placed in asquare configuration 63 with respect to one another with a space betweenadjacent corners. A plurality of octagonal shape metal fins 64, eachoctagonal shape metal fin 64 is comprised of four bodies 66; each body66 is of long fins 65 and short fins 67. The individual bodies areassembled together by fastening means 68. Each octagonal shape metalfins 64 has four slots 69 emanating from the same and equidistance fromone another is then interlock with the flat plates 61 via the slottingmethod so as to “fill in” the corners of the square.

There are several advantages of using interlocking metal foundationsover other metal foundations. To achieve the same strength requires lessmaterial. This ultimately makes the interlocking foundations moreeconomical than other metal foundations such as radial and perimeterfoundations. Studies have shown that when an interlocking foundationutilizes the same footprint as a previous metal foundation there is a65% increase in strength, with interlocking foundation beingapproximately 40% cheaper to produce and assemble. If one desires aninterlocking foundation to have the same footprint and the same strengthof a previous metal foundation, the cost of the interlocking foundationis ˜80% less.

1. An interlocking foundation comprising: a bottom plate with an upwardslot and a top plate with a downward slot; whereby the upward slot andthe downward slot are used to interlock the bottom plate and the topplate to form an interlocking foundation.
 2. The interlocking foundationof claim 1, further comprising a top mounting plate, the top mountingplate comprising a flat plate and a plurality of side overhangs.
 3. Theinterlocking foundation of claim 1, wherein the upward slot and thedownward slot are centered within their respective plates.
 4. Theinterlocking foundation of claim 1, wherein the bottom plate and the topplate are identical in size and shape.
 5. An interlocking pipe supportfoundation comprising: a bottom plate with a central upward slot and twoupward pipe slots on the same side of the bottom plate; each upward pipeslot being equidistant from the central upward slot; a top plate with acentral downward slot and two upward pipe slots; the central downwardslot and two upward slots being on opposite sides of the top plate; eachupward pipe slot being equidistant from the central downward slot;whereby the central upward slot and the central downward slot are usedto interlock the bottom plate and the top plate to form a basefoundation; a pipe with downward receiving slots that align with theupward pipe slots of the base foundation; whereby the upward pipe slotsand the downward receiving slots interlock to form an interlocking pipesupport foundation.
 6. An interlocking angle foundation comprising: abottom plate comprised of two legs connected at an angle to one another,each leg comprised of an angled leg flange, and each leg comprised of anupward slot; a top plate comprised of two legs connected at an angle toone another, each leg comprised of an angled leg flange and each legcomprised of a downward slot; whereby the upwards slots and the downwardslots are used to interlock the bottom plate and the top plate to forman interlocking angle foundation comprised of a central tube and fourbent fins.
 7. The interlocking angle foundation of claim 6 wherein thetwo legs are connected to one another at a 90 degree angle.
 8. Theinterlocking angle foundation of claim 6 wherein each angled leg flangeis angled at 90) degrees to its respective leg.
 9. The interlockingangle foundation of claim 6, further comprising a top mounting plate,the top mounting plate comprising a flat plate and a plurality of sideoverhangs.
 10. The interlocking angle foundation of claim 6, wherein thebottom plate and the top plate are identical in size and shape.